Welding method

ABSTRACT

One aspect of the present disclosure is a welding method including welding an upper plate and a lower plate overlapped with the upper plate by irradiating a surface of the upper plate with a laser beam. The welding includes forming a main welding path that intersects a welding advancing direction and that includes turning points. The upper plate and the lower plate are arranged in an inclined manner with respect to a horizontal plane when viewed parallel to the welding advancing direction. In the forming the main welding path, an amount of energy applied by the laser beam in an area in a neighborhood of the turning point on a vertically upper side is designed to be larger than an amount of energy applied by the laser beam in an area in a neighborhood of the turning point on a vertically lower side.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of Japanese Patent Application No.2018-197703 filed on Oct. 19, 2018 with the Japan Patent Office, theentire disclosure of which is incorporated herein by reference.

BACKGROUND

The present disclosure relates to a welding method.

A method is known for irradiating welding-target metal members with alaser beam to thereby weld the metal members together (see PublishedJapanese Translation of PCT International Patent Application No.2005-527383). Such laser welding is also used to weld two overlappingmetal plates.

SUMMARY

In a case where the two metal plates are arranged in an inclined mannerwith respect to a horizontal plane and also where an interspace betweenthe two metal plates when overlapped is large, a conventional weldingmethod may fail to sufficiently fill the interspace between the metalplates with molten metal, resulting in the risk of poor welding.

It is desirable that one aspect of the present disclosure provide awelding method enabling enhancement of quality of welding between anupper plate and a lower plate arranged in an inclined manner.

One aspect of the present disclosure is a welding method comprisingwelding an upper plate and a lower plate overlapped with the upper plateby irradiating a surface of the upper plate with a laser beam. Thewelding comprises forming a main welding path that intersects a weldingadvancing direction and that comprises turning points. The upper plateand the lower plate are arranged in an inclined manner with respect to ahorizontal plane when viewed parallel to the welding advancingdirection. In the forming the main welding path, an amount of energyapplied by the laser beam in an area in a neighborhood of the turningpoint on a vertically upper side is designed to be larger than an amountof energy applied by the laser beam in an area in a neighborhood of theturning point on a vertically lower side.

In such a configuration, a larger amount of energy is applied in theneighborhood of the turning point on the vertically upper side, wherethe molten metal is liable to run down, than in the neighborhood of theturning point on the vertically lower side. This enables reduction ofoccurrence of excessive melting in the neighborhood of the turning pointon the vertically lower side, and also enables compensation forinsufficiency of the molten metal in the neighborhood of the turningpoint on the vertically upper side. As a result, the welding quality canbe enhanced. In addition, the inclined arrangement of the upper plateand the lower plate can increase the design margin of products and jigs.

In one aspect of the present disclosure, in the forming the main weldingpath, a welding speed in the area in the neighborhood of the turningpoint on the vertically upper side may be designed to be lower than awelding speed in the area in the neighborhood of the turning point onthe vertically lower side. Such a configuration enables easy andreliable adjustment of the amount of energy in the neighborhood of theturning points.

In one aspect of the present disclosure, in the forming the main weldingpath, movement of the laser beam may be stopped for a specified periodof time in the area in the neighborhood of the turning point on thevertically upper side while irradiation with the laser beam iscontinued. Such a configuration enables easy and reliable reduction ofthe welding speed in the neighborhood of the turning point on thevertically upper side.

In one aspect of the present disclosure, the welding may furthercomprise stopping irradiation with the laser beam after formation of themain welding path and then performing re-irradiation. Such aconfiguration enables slow cooling at the end point of welding. As aresult, occurrence of solidification cracking at the end point ofwelding can be reduced.

In one aspect of the present disclosure, the welding may furthercomprise forming an auxiliary welding path that is continuous andcomprises a reciprocating or circling path, prior to the forming themain welding path. Such a configuration makes it possible to generatethe molten metal in the auxiliary welding path to supply the moltenmetal to the main welding path. This can reduce generation of a gap dueto insufficiency of the molten metal in the main welding path.

In one aspect of the present disclosure, the auxiliary welding path mayhave a circular shape. Such a configuration facilitates formation of achamber for the molten metal, thus enabling the molten metal to besupplied to the main welding path easily and reliably.

In one aspect of the present disclosure, the main welding path maycomprise: an initial region continuous from the auxiliary welding path;and a subsequent region that is provided on a more forward side of thewelding advancing direction than the initial region and that has alarger turnaround pitch than the initial region. Such a configurationmakes it possible to effectively utilize the molten metal in theneighborhood of the start point of the main welding path, and also toseek reduction of time for forming the main welding path.

BRIEF DESCRIPTION OF THE DRAWINGS

Example embodiments of the present disclosure will be described belowwith reference to the accompanying drawings, in which:

FIG. 1 is a flow and block diagram of a welding apparatus used in awelding method of an embodiment;

FIG. 2A is a schematic perspective view of a welded portion in thewelding method in FIG. 1, and FIG. 2B is a schematic diagram of thewelded portion in the welding method in FIG. 1;

FIG. 3A is a schematic diagram of an auxiliary welding path, FIG. 3B isa schematic diagram of an auxiliary welding path of an embodiment otherthan shown in FIG. 3A, and FIG. 3C is a schematic diagram of a mainwelding path;

FIG. 4 is a schematic diagram showing relationships between a weldingadvancing direction and an energy level or a welding speed;

FIG. 5 is a schematic diagram showing relationships between time and anenergy level or a temperature at the end of welding;

FIG. 6 is a flow chart of the welding method of the embodiment;

FIG. 7 is a flow chart of a low-pitch main welding path forming process;

FIG. 8 is a flow chart of a high-pitch main welding path formingprocess; and

FIG. 9 is a schematic sectional view of the welded portion.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 1. First Embodiment 1-1.Configuration

A welding method of the present embodiment comprises a welding processof welding an upper plate and a lower plate overlapped with the upperplate by irradiating a surface of the upper plate with a laser beam.

In the welding method of the present embodiment, welding is performedusing a welding apparatus 10 shown in FIG. 1. The welding apparatus 10comprises an oscillator 12, a mirror 13, a motor 14, and a controller15.

In the welding method of the present embodiment, an upper plate 3 and alower plate 2 are arranged in an inclined manner with respect to ahorizontal plane when viewed parallel to a welding advancing direction(i.e., a direction normal to the paper of FIG. 1). Specifically, theupper plate 3 and the lower plate 2 are rotated away from a horizontalplane about a roll axis parallel to the welding advancing direction. Anangle of inclination (i.e., a roll angle) a of the upper plate 3 and thelower plate 2 with respect to the horizontal plane is more than 0° andless than 90°.

The oscillator 12 generates a laser beam that applies energy to an uppersurface of the upper plate 3 (i.e., a base material surface) overlappedwith the lower plate 2. Examples of a usable source of supply of thelaser beam may include carbon dioxide gas (CO₂). The mirror 13 redirectsa path of the laser beam generated by the oscillator 12, and irradiatesthe surface of the upper plate 3 with the laser beam. The motor 14 ismounted to the mirror 13, and is configured to change an angle of themirror 13.

The controller 15 adjusts an irradiation position and an amount ofenergy of the laser beam on the surface of the upper plate 3.Specifically, the controller 15 adjusts the irradiation position of thelaser beam by changing the angle of the mirror 13 via the motor 14.Also, the controller 15 adjusts the amount of energy of the laser beamby varying output of the oscillator 12.

A specific procedure for adjusting the welding apparatus 10 will bedescribed below. As shown in FIG. 1, firstly, an operator inputs a laseroutput (laser power output target value) and a welding speed directlyinto the welding apparatus 10 within a program (step S1).

In parallel with the step S1, the operator may determine a weldingposition visually and teaches it to the welding apparatus 10, to therebyautomatically generate a welding position within the program (step S2).Also, the operator may determine (generate) the welding position bynumerical input (step S3).

The controller 15 creates a coordinate system (step S4) based on theinputs performed in the step S2 and/or the step S3. It is also possibleto choose and execute only either one of the step S2 or the step S3.

Based on the input in the step S1 (i.e., the laser output and thewelding speed) and the coordinate system created in the step S4, thecontroller 15 creates a motion pattern of the welding apparatus 10 as awhole by means of a motion controller (step S5).

The controller 15 issues a laser output command to the oscillator 12based on the motion pattern created in the step S5 (step S6). Also, thecontroller 15 issues an irradiation position command to a processinghead comprising the mirror 13 and the motor 14 (step S7). The step S6and the step S7 are linked to each other.

<Weld Structure>

The welding by the welding apparatus 10 results in obtaining a weldstructure 1 shown in FIG. 2A. The weld structure 1 is a structure withtwo metal plates welded together in a thickness direction thereof. Theweld structure 1 comprises the lower plate 2 (including a first surface2A that is an upper surface of the lower plate 2, and including a secondsurface 2B that is a lower surface of the lower plate 2), the upperplate 3 (including a third surface 3A that is an upper surface of theupper plate 3, and including a fourth surface 3B that is a lower surfaceof the upper plate 3), a main welding portion 4, and a welding bead 6.

Application of the weld structure 1 is not limited in particular as longas metal plates are to be welded together. The weld structure 1 can beused suitably for, for example, bracket mounting structures forautomobile parts, such as an instrument panel reinforcement.

Examples of materials of the lower plate 2 may include iron, iron alloysuch as steel, aluminum, or aluminum alloy. The thickness of the lowerplate 2 is not limited in particular. Examples of materials of the upperplate 3 may include those listed as the materials of the lower plate 2.The materials of the upper plate 3 and the lower plate 2 may beidentical to each other or may be different from each other.

A portion of the upper plate 3 is overlapped with the first surface 2Aof the lower plate 2 (an upper surface in FIG. 2A). The upper plate 3may be a thin plate having an average thickness of 1 mm or smaller in anoverlapping area O where it is overlapped with the lower plate 2. Theupper plate 3 may be entirely overlapped with the lower plate 2. Theaverage thickness of the upper plate 3 not in the overlapping area O maybe larger than 1 mm.

In a welded portion, the main welding portion 4 is a portion where themetals constituting the lower plate 2 and the upper plate 3 have beenmelted and solidified due to heat input by the laser beam. The weldingbead 6 is formed around the main welding portion 4. As shown in FIG. 2B,the main welding portion 4 comprises a circular part 4A and a waved part4B.

The circular part 4A in the main welding portion 4 is created by anauxiliary welding path 41 of the laser beam shown in FIG. 3A. The wavedpart 4B of the main welding portion 4 is created by a main welding path42 of the laser beam.

The welding process in the welding method of the present embodimentcomprises an auxiliary welding path forming process for forming theauxiliary welding path 41, a main welding path forming process forforming the main welding path 42, and a re-irradiation process forstopping irradiation with the laser beam after formation of the mainwelding path 42 and then performing re-irradiation.

<Auxiliary Welding Path Forming Process>

In this process, formed prior to the main welding path forming processis the auxiliary welding path 41, which is continuous and comprises areciprocating or circling path, or a plurality of the auxiliary weldingpaths 41. In the present embodiment, as shown in FIG. 3A, the auxiliarywelding path 41 with a circular shape, which is a circling path, isformed. The “circular shape” is a concept including an approximatelyspiral shape with its diameter reduced or enlarged along acircumferential direction.

For example, the auxiliary welding path 41 with a circular shape isformed by firstly depicting a semicircle with a specified diameter froma start point S of irradiation with the laser beam along a weldingadvancing direction L, secondly depicting a semicircle with a slightlylarger diameter toward the start point S, and then depicting asemicircle with an even larger diameter along the welding advancingdirection L.

Occurrence of blowholes can be reduced by arranging the circling path ina non-overlapping manner as described above. Further, formation of thepath into the circular shape facilitates formation of a chamber C formolten metal. Thus, the molten metal can be suitably supplied to themain welding path 42.

As shown in FIG. 3B, the auxiliary welding path 41 may have anapproximately rectangular shape (created from line segments).

Alternatively, the auxiliary welding path 41 may have a polygonal shapeother than the rectangular shape. Furthermore, the auxiliary weldingpath 41 may be a linear path reciprocating in specified directions.

<Main Welding Path Forming Process>

In this process, formed after the formation of the auxiliary weldingpath 41 is the main welding path 42 that intersects the weldingadvancing direction L and that comprises multiple turning points.

As shown in FIG. 3A, a start point of the main welding path 42 is an endpoint Q3 of the auxiliary welding path 41. That is, the main weldingpath 42 is formed continuously with the auxiliary welding path 41. Asshown in FIG. 3C, the main welding path 42 is configured to turn aroundin directions intersecting the welding advancing direction L so as tocross a center line M parallel to the welding advancing direction L.

In the present embodiment, the main welding path 42 has a triangularwaveform. The main welding path 42 having a shape in which it turnsaround gently at the tops of the triangular waveforms or having asinusoidal waveform may also be adopted.

The main welding path 42 is formed by irradiating the third surface 3Aof the upper plate 3 (an upper surface in FIG. 2A), which is on anopposite side from the lower plate 2, with the laser beam while weavingit with respect to the welding advancing direction L.

The main welding path 42 comprises an initial region 42A continuous fromthe auxiliary welding path 41 and a subsequent region 42B provided on amore forward side of the welding advancing direction L than the initialregion 42A. A subsequent turnaround pitch P2 in the subsequent region42B is larger than an initial turnaround pitch P1 in the initial region42A.

Here, the “turnaround pitch” means the length in the welding advancingdirection L of one cycle (i.e., one wavelength) of the path in eachregion. Specifically, the turnaround pitch is a distance between twofarthermost intersections from among three adjacent intersections wherethe path in each region intersects the center line M.

As described above, the initial turnaround pitch P1 in the initialregion 42A is smaller than the subsequent turnaround pitch P2 in thesubsequent region 42B. As shown in FIG. 3A, this reduces a distancebetween the chamber C for the molten metal and a turning point Q1 (aninitial turning point) on a vertically upper side of the main weldingpath 42. As a result, supply of the molten metal from the chamber C tothe turning point Q1 is facilitated. In addition, the auxiliary weldingpath 41 and the initial region 42A may be integrally formed (notseparated by a gap).

In the present embodiment, the main welding path 42 in the initialregion 42A has a length of one cycle including the initial turningpoints Q1 and Q2. That is, the length of the initial region 42A in thewelding advancing direction L is equal to the initial turnaround pitchP1 in the initial region 42A.

The main welding path 42 in the subsequent region 42B has multiplecycles. The subsequent region 42B is a region extending from an endpoint Q4 in the initial region 42A to a finish point F of welding. Inthe present embodiment, the length of the subsequent region 42B in thewelding advancing direction L is an integral multiple of the subsequentturnaround pitch P2 in the subsequent region 42B.

In the present embodiment, an amount of energy applied by the laser beamin an area R1 in the neighborhood of the turning point Q1 on thevertically upper side is designed to be larger than an amount of energyapplied by the laser beam in an area R2 in the neighborhood of theturning point Q2 on a vertically lower side.

Specifically, the welding speed in the area R1 in the neighborhood ofthe turning point Q1 on the vertically upper side is designed to belower than the welding speed in the area R2 in the neighborhood of theturning point Q2 on the vertically lower side. In other words,irradiation time of the laser beam in the area R1 in the neighborhood ofthe turning point Q1 on the vertically upper side is designed to belonger than irradiation time of the laser beam in the area R2 in theneighborhood of the turning point Q2 on the vertically lower side.

As shown in FIG. 4, this makes the amount of energy applied in theneighborhood of the turning point Q1 on the vertically upper side of themain welding path 42 larger than the amount of energy applied to theturning point Q2 on the vertically lower side.

As a means for varying the welding speed in the neighborhood of eachturning point as above, a timer can be used. Specifically, the weldingspeed in the area R1 in the neighborhood of the turning point Q1 on thevertically upper side can be lowered than the welding speed in the areaR2 in the neighborhood of the turning point Q2 on the vertically lowerside by stopping movement of the laser beam for a specified period oftime in the area R1 in the neighborhood of the turning point Q1 on thevertically upper side while irradiation with the laser beam iscontinued.

The period of time in which the laser beam is stopped using the timermay be set to, for example, 0.01 second or longer and 1 second orshorter. Output of the laser beam may be varied while movement of thelaser beam is stopped.

Further, in the present embodiment, the amount of energy applied in theareas R1 and R2 in the neighborhood of the turning points Q1 and Q2,respectively, is smaller than the amount of energy applied in areas notin the neighborhood of the turning point Q1 or Q2. This can reduceoccurrence of hole opening due to excessive penetration at the turningpoints Q1 and Q2.

Specifically, as shown in FIG. 4, the welding speed in the area R1 inthe neighborhood of the turning point Q1 on the vertically upper sideand the welding speed in the area R2 in the neighborhood of the turningpoint Q2 on the vertically lower side are designed to be higher than thewelding speed in areas other than the areas R1 and R2.

<Re-Irradiation Process>

In this process, irradiation with the laser beam is stopped at thefinish point F of welding, and then, re-irradiation with the laser beamis applied to the finish point F.

An interval between the stop of irradiation and the re-irradiation maybe set to, for example, 0.05 second or longer and 2 seconds or shorter.The period of time for re-irradiation may be set to, for example, 0.05second or longer and 2 seconds or shorter.

Output of the laser beam at the time of the re-irradiation may be variedfrom the output during the welding (i.e., during formation of the mainwelding path 42) by, for example, defocusing or the like. However, it ispreferable to set the same output as that during the welding.

As shown in FIG. 5, irradiation with the laser beam is stopped at a timeT1 and re-irradiation is performed at a time T2, thus extending a timeperiod for cooling at the finish point F and delaying the end of thetime period from a time T3 to a time T4. That is, the finish point F isallowed to cool slowly, and thus, occurrence of solidification crackingis reduced.

<Control>

A process that the welding apparatus 10 performs to achieve the weldingmethod of the present embodiment will be described below with referenceto a flow chart in FIG. 6.

Firstly, the welding apparatus 10 forms the auxiliary welding path 41 byusing the oscillator 12 and the motor 14 (step S10). After forming theauxiliary welding path 41, the welding apparatus 10 performs a low-pitchmain welding path forming process in FIG. 7 (step S20).

In the low-pitch main welding path forming process, the weldingapparatus 10 firstly sets a welding pitch at a low pitch (i.e., theinitial turnaround pitch P1 in the initial region 42A) (step S110).

Next, the welding apparatus 10 locates the current irradiation position,and determines whether the current irradiation position is in theneighborhood of the turning point Q1 or Q2 (step S120). If the currentirradiation position is in the neighborhood of the turning point Q1 orQ2 (S120: YES), the welding apparatus 10 issues a command to switch thewelding speed to a high-speed mode or a command to keep the high-speedmode (step S130).

Contrarily, if the current irradiation position is not in theneighborhood of the turning point Q1 or Q2 (S120: NO), the weldingapparatus 10 issues a command to shift the welding speed to a low-speedmode or a command to keep the low-speed mode (step S140).

The welding apparatus 10 repeatedly performs control of the weldingspeed until the irradiation position reaches the turning point Q1 (stepS150). After the irradiation position reaches the turning point Q1, thewelding apparatus 10 stops at the turning point Q1 for a specifiedperiod of time using the timer while continuing irradiation with thelaser beam (step S160).

Upon lapse of the specified period of time, the welding apparatus 10determines again whether the current irradiation position is in theneighborhood of the turning point Q1 or Q2 while welding at low pitch(step S170), and performs shifting between the high-speed mode (stepS180) and the low-speed mode (step S190). When the irradiation positionreaches the end point Q4 of the initial region 42A, the weldingapparatus 10 ends the low-pitch main welding path forming process (stepS200).

After completion of the low-pitch main welding path forming process, thewelding apparatus 10 performs a high-pitch main welding path formingprocess in FIG. 8 (step S30).

In the high-pitch main welding path forming process, the weldingapparatus 10 firstly sets the welding pitch at a high pitch (i.e., thesubsequent turnaround pitch P2 in the subsequent region 42B) (stepS210).

Next, the welding apparatus 10 locates the current irradiation position,and determines whether the current irradiation position is in theneighborhood of the turning point Q1 or Q2 (step S220). If the currentirradiation position is in the neighborhood of the turning point Q1 orQ2 (S220: YES), the welding apparatus 10 issues a command to shift thewelding speed to a high-speed mode or a command to keep the high-speedmode (step S230).

Contrarily, if the current irradiation position is not in theneighborhood of the turning point Q1 or Q2 (S220: NO), the weldingapparatus 10 issues a command to shift the welding speed to a low-speedmode or a command to keep the low-speed mode (step S240).

The welding apparatus 10 repeatedly performs control of the weldingspeed until the irradiation position reaches the turning point Q1 (stepS250). After the irradiation position reaches the turning point Q1, thewelding apparatus 10 stops at the turning point Q1 for a specifiedperiod of time using the timer while continuing irradiation with thelaser beam (step S260).

Upon lapse of the specified period of time, the welding apparatus 10determines again whether the current irradiation position is in theneighborhood of the turning point Q1 or Q2 while welding at high pitch(step S270), and performs shifting between the high-speed mode (stepS280) and the low-speed mode (step S290). When the irradiation positionreaches an end point Q5 for each cycle of the main welding path 42, thewelding apparatus 10 ends the high-pitch main welding path formingprocess (step S300).

After completion of each cycle of the high-pitch main welding pathforming process, the welding apparatus 10 determines whether theirradiation position reaches the finish point F of welding (step S40 inFIG. 6). If the irradiation position does not reach the finish point F(S40: NO), the welding apparatus 10 repeats the high-pitch main weldingpath forming process.

If the irradiation position reaches the finish point F (S40: YES), thewelding apparatus 10 stops irradiation with the laser beam (step S50).Upon lapse of a specified period of time, the welding apparatus 10performs re-irradiation with the laser beam (step S60).

<Cross-Section of Weld Structure>

A cross-section of the weld structure obtained by the welding method ofthe present embodiment is shown in FIG. 9. FIG. 9 illustrates the weldstructure welded in an inclined state where the right side thereof inFIG. 9 is positioned upper in the vertical direction. The outline arrowin the drawing indicates a direction of irradiation with the laser beam.

In the weld structure in FIG. 9, no voids (i.e., blowholes) are presentwithin the main welding portion 4. Molten metal 5 constituting the mainwelding portion 4 is formed more on the vertically upper side than onthe vertically lower side. In other words, a larger amount of the moltenmetal is generated on the vertically upper side so as to compensate forthe molten metal that runs down by gravity.

The molten metal 5 penetrates the upper plate 3, and reaches the insideof the lower plate 2 and then the second surface 2B (a lower surface inFIG. 9), which is on an opposite side from the upper plate 3. The upperplate 3 and the lower plate 2 are welded together in the thicknessdirection thereof via the main welding portion 4 welded on an innersurface of the upper plate 3 and on an inner surface of the lower plate2.

The third surface 3A (i.e., a welding surface) of the upper plate 3,which is on an opposite side from the lower plate 2, and an (upper)exposed surface 4C of the main welding portion 4 in the upper plate 3are continuous. That is, in the cross-section perpendicular to alongitudinal direction (i.e., the welding advancing direction) of themain welding portion 4, there are no steps in the thickness direction atconnections between the upper plate 3 and the main welding portion 4.The longitudinal direction of the main welding portion 4 is a weavingadvancing direction (i.e., a direction parallel to a line connecting thecenters in the weaving).

The (upper) exposed surface 4C of the main welding portion 4 is curvedin a concave shape recessed in the thickness direction of the upperplate 3. In other words, the exposed surface 4C is like a bridge betweentwo ends on the third surface 3A of the upper plate 3, which are spacedapart by the molten metal 5, and smoothly connects these ends to eachother.

As shown in FIG. 9, the main welding portion 4 within the upper plate 3increases in width from the third surface 3A of the upper plate 3 towardan inner side in the thickness direction (i.e., as getting closer to thelower plate 2). However, such increase in width of the main weldingportion 4 within the upper plate 3 is not essential.

Also, the width of the main welding portion 4 within the lower plate 2decreases in width from the first surface 2A of the lower plate 2 towardan outer side in the thickness direction (i.e., as spaced apart from theupper plate 3). A bottom surface 4D of the main welding portion 4exposed from the lower plate 2 has a smaller width in a directionperpendicular to the thickness direction than the exposed surface 4C ofthe main welding portion 4 in the upper plate 3.

As shown in FIG. 9, there exists an interspace D in an overlappingdirection between the fourth surface 3B of the upper plate 3 (a lowersurface in FIG. 9), which faces the lower plate 2, and the first surface2A of the lower plate 2. If this interspace D is too large, it is fearedthat the weld strength may be insufficient. The interspace D between theupper plate 3 and the lower plate 2 does not necessarily have to exist.

1-2. Effects

The above-detailed embodiment provides effects below.

(1a) A larger amount of energy is applied in the neighborhood of theturning point Q1 on the vertically upper side, where the molten metal isliable to run down, than in the neighborhood of the turning point Q2 onthe vertically lower side. This enables reduction of occurrence ofexcessive melting in the neighborhood of the turning point Q2 on thevertically lower side, and also enables compensation for insufficiencyof the molten metal in the neighborhood of the turning point Q1 on thevertically upper side. As a result, the welding quality can be enhanced.In addition, the inclined arrangement of the upper plate 3 and the lowerplate 2 can increase the design margin of products and jigs.

(1b) Movement of the laser beam is stopped for the specified period oftime in the area R1 in the neighborhood of the turning point Q1 on thevertically upper side while irradiation with the laser beam iscontinued. This decreases the welding speed in the neighborhood of theturning point Q1 on the vertically upper side, thus enabling easy andreliable adjustment of the amount of energy in the neighborhood of theturning points Q1 and Q2.

(1c) Irradiation with the laser beam is stopped at the end point ofwelding, and then re-irradiation is performed. This enables slow coolingat the end point of welding. As a result, occurrence of solidificationcracking at the end point of welding can be reduced.

(1d) The molten metal is generated in the auxiliary welding path 41, andthe molten metal can be supplied to the main welding path 42. This canreduce generation of a gap due to insufficiency of the molten metal inthe main welding path 42.

(1e) The main welding path 42 comprises the initial region 42A and thesubsequent region 42B having the larger turnaround pitch than theinitial region 42A. This makes it possible to effectively utilize themolten metal in the neighborhood of the start point of the main weldingpath 42, and also to seek reduction of time for the process of formingthe main welding path 42.

2. Other Embodiments

The embodiment of the present disclosure has been described so far;however, the present disclosure is not limited to the aforementionedembodiment and can take various forms.

(2a) In the welding method of the aforementioned embodiment, the amountof energy applied in the neighborhood of the turning point Q1 on thevertically upper side may be designed to be larger than the amount ofenergy applied in the neighborhood of the turning point Q2 on thevertically lower side by controlling the output of the laser beam or thefocus of the laser beam, instead of the welding speed or in combinationwith the welding speed.

In adjusting the welding speed at the turning point Q1, movement of thelaser beam does not necessarily have to be stopped for the specifiedperiod of time. Specifically, the welding speed at the turning point Q1may be adjusted by a control decreasing the welding speed.

Furthermore, instead of designing the amount of energy applied in thearea R1 in the neighborhood of the turning point Q1 on the verticallyupper side to be larger than the amount of energy applied in the otherareas, the amount of energy applied in the area R2 in the neighborhoodof the turning point Q2 on the vertically lower side may be designed tobe smaller than the amount of energy applied in the other areas.

(2b) In the welding method of the aforementioned embodiment, the mainwelding path 42 does not necessarily have to comprise the initial region42A and the subsequent region 42B. Specifically, the turnaround pitch ofthe main welding path 42 may be constant.

(2c) In the welding method of the aforementioned embodiment, theauxiliary welding path forming process is not an essential process.Thus, welding may be started from the start point of the main weldingpath 42. Further, the re-irradiation process is also not an essentialprocess and thus may be omitted.

(2d) In the welding method of the aforementioned embodiment, the amountof energy applied in the areas R1 and R2 in the neighborhood of theturning points Q1 and Q2, respectively, does not necessarily have to besmaller than the amount of energy applied in the areas other than in theneighborhood of the turning points Q1 and Q2.

(2e) The function(s) performed by a single element in the aforementionedembodiments may be performed by multiple elements. The function(s)performed by multiple elements may be performed by a single element.Part of the configuration of the aforementioned embodiments may beomitted. At least part of the configuration of the aforementionedembodiments may be added to or replaced by the configuration of theaforementioned other embodiments. All modes included in the technicalidea specified by recitations in the accompanying claims are embodimentsof the present disclosure.

What is claimed is:
 1. A welding method comprising welding an upperplate and a lower plate overlapped with the upper plate by irradiating asurface of the upper plate with a laser beam, the welding comprising:forming a main welding path that intersects a welding advancingdirection and that comprises turning points; and forming an auxiliarywelding path, which is continuous and comprises a reciprocating orcircling path, prior to the forming the main welding path, the upperplate and the lower plate being arranged in an inclined manner withrespect to a horizontal plane when viewed parallel to the weldingadvancing direction, and in the forming the main welding path, an amountof energy applied by the laser beam in an area in a neighborhood of atleast one of the turning points on a vertically upper side beingdesigned to be larger than an amount of energy applied by the laser beamin an area in a neighborhood of at least one of the turning points on avertically lower side, wherein the main welding path comprises: aninitial region continuous from the auxiliary welding path; and asubsequent region that is provided on a more forward side of the weldingadvancing direction than the initial region and that has a largerturnaround pitch along the welding advancing direction than the initialregion.
 2. The welding method according to claim 1, wherein, in theforming the main welding path, a welding speed in the area in theneighborhood of at least one of the turning points on the verticallyupper side is designed to be lower than a welding speed in the area inthe neighborhood of at least one of the turning points on the verticallylower side.
 3. The welding method according to claim 2, wherein, in theforming the main welding path, movement of the laser beam is stopped fora specified period of time in the area in the neighborhood of at leastone of the turning points on the vertically upper side while irradiationwith the laser beam is continued.
 4. The welding method according toclaim 1, wherein the welding further comprises stopping irradiation withthe laser beam after formation of the main welding path and thenperforming re-irradiation.
 5. The welding method according to claim 5claim 1, wherein the auxiliary welding path has a circular shapethecircling path.
 6. The welding method according to claim 4, whereinoutput of the laser beam in the performing the re-irradiation is thesame as an output of the laser beam in the forming the main weldingpath.
 7. The welding method according to claim 1, wherein the weldingadvancing direction is linear.